U.S. patent application number 16/632026 was filed with the patent office on 2020-05-14 for footwear.
The applicant listed for this patent is W. L. Gore & Associates GmbH W. L. Gore & Associati S.R.L.. Invention is credited to Andrea Giupponi, Jens Heidenfelder, Amr Mahmoud Hamdy Kobaisy Ali, Alexander Zaggl.
Application Number | 20200146390 16/632026 |
Document ID | / |
Family ID | 59593015 |
Filed Date | 2020-05-14 |
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United States Patent
Application |
20200146390 |
Kind Code |
A1 |
Heidenfelder; Jens ; et
al. |
May 14, 2020 |
FOOTWEAR
Abstract
Footwear (2) includes an upper assembly (4) having an outer
construction (40, 42) and further having a bootie (50) made with a
waterproof, breathable laminate, the waterproof, breathable
laminate (51) including a one-piece functional layer (54) and at
least one textile layer (56, 58), and a sole (6) attached to the
upper assembly, wherein the bootie has elasticity in a
circumferential direction of the bootie, wherein the bootie is
fixed in position in a toe region (90) of the footwear and fixed in
position in a heel region (96) of the footwear, and wherein the
bootie is not attached to the outer construction on an upper side
of a midfoot portion (92) of the bootie.
Inventors: |
Heidenfelder; Jens;
(Zorneding, DE) ; Kobaisy Ali; Amr Mahmoud Hamdy;
(Munchen, DE) ; Zaggl; Alexander; (Aying, DE)
; Giupponi; Andrea; (Verona, IT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
W. L. Gore & Associates GmbH
W. L. Gore & Associati S.R.L. |
Putzbruss
Verona |
|
DE
IT |
|
|
Family ID: |
59593015 |
Appl. No.: |
16/632026 |
Filed: |
July 17, 2017 |
PCT Filed: |
July 17, 2017 |
PCT NO: |
PCT/EP2017/068030 |
371 Date: |
January 17, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 23/06 20130101;
A43B 23/0235 20130101; A43B 7/125 20130101; A43B 23/07
20130101 |
International
Class: |
A43B 7/12 20060101
A43B007/12; A43B 23/07 20060101 A43B023/07; A43B 23/02 20060101
A43B023/02 |
Claims
1. Footwear (2) comprising: an upper assembly (4) comprising an
outer construction (40, 42) and further comprising a bootie (50)
made with a waterproof, breathable laminate, the waterproof,
breathable laminate (51) comprising a one-piece functional layer
(54) and at least one textile layer (56, 58), and a sole (6)
attached to the upper assembly, wherein the bootie has elasticity
in a circumferential direction of the bootie, wherein the bootie is
fixed in position in a toe region (90) of the footwear and fixed in
position in a heel region (96) of the footwear, and wherein the
bootie is not attached to the outer construction on an upper side
of a midfoot portion (92) of the bootie.
2. Footwear (2) according to claim 1, wherein an air gap (52) is
present between the bootie (50) and the outer construction (40, 42)
on the upper side of the midfoot portion (92) of the bootie.
3. Footwear (2) according to claim 1 or 2, wherein the bootie (50)
and the outer construction (40, 42) are jointly extendable on the
upper side of the midfoot portion (92) of the bootie.
4. Footwear (2) according to any of the preceding claims, wherein
the midfoot portion (92) extends along at least 80%, in particular
along at least 90%, further in particular along 100%, of the length
from a foot instep portion of the upper assembly corresponding to a
navicular area of a foot forward to a ball portion of the upper
assembly corresponding to metatarsal point 1--phalanges joint of
the foot.
5. Footwear (2) according to any of the preceding claims, wherein
the midfoot portion (92) extends along at least 80%, in particular
along at least 90%, further in particular along 100%, of the length
from an upper tongue portion of the outer construction forward to a
toe box area of the outer construction.
6. Footwear (2) according to any of the preceding claims, wherein
the bootie (50) is not attached to the outer construction (40,42)
around at least 50%, in particular around at least 60%, further in
particular around at least 65%, of the circumference of the bootie
in the midfoot portion (92).
7. Footwear (2) according to any of the preceding claims, wherein
the one-piece functional layer is seamless on the upper side of the
midfoot portion (92) of the bootie (50).
8. Footwear (2) according to any of the preceding claims, wherein
the one-piece functional layer is a seamless, one-piece functional
layer.
9. Footwear (2) according to any of the preceding claims, wherein
the upper assembly (4) comprises an assembly insole (44) and
wherein the bootie (50) is attached to at least one of the outer
construction (40, 42) and the assembly insole in the toe region
(90) and to at least one of the outer construction and the assembly
insole in the heel region (96).
10. Footwear (2) according to claim 9, wherein the bootie (50) is
not attached to the assembly insole (44) on a lower side of the
midfoot portion (92) of the bootie.
11. Footwear (2) according to any of claims 1 to 8, wherein the
bootie (50) forms an outermost lower part of the upper assembly (4)
towards the sole (6) of the footwear and wherein the bootie is
attached to at least one of the outer construction (40, 42) of the
upper assembly and the sole in the toe region (90) and to at least
one of the outer construction of the upper assembly and the sole in
the heel region (96).
12. Footwear (2) according to claim 11, wherein the bootie (50) is
not attached to the sole (6) on a lower side of the midfoot portion
(92) of the bootie.
13. Footwear (2) according to any of the preceding claims, wherein
the bootie (50) is attached to the outer construction (40, 42) of
the upper assembly (4) in a collar region (98) of the footwear.
14. Footwear (2) according to any of the preceding claims, wherein
the bootie (50) has a midfoot circumference in the midfoot portion
(92) that is between 60% and 99%, in particular between 70% and
95%, further in particular between 80% and 90%, of a foot
circumference in the midfoot portion.
15. Footwear (2) according to any of the preceding claims, wherein
the bootie (50) has elasticity in a longitudinal direction of the
bootie.
16. Footwear (2) according to claim 15, wherein the bootie (50) has
a longitudinal elasticity of at most 15 N/cm, in particular of at
most 5 N/cm, at 10% elongation in the longitudinal direction of the
bootie.
17. Footwear (2) according to any of the preceding claims, wherein
the bootie (50) has a circumferential elasticity of at most 15
N/cm, in particular of at most 5 N/cm, at 30% elongation in the
circumferential direction of the bootie.
18. Footwear (2) according to any of the preceding claims, wherein
the bootie (50) has an elastic recovery of at least 75% in at least
one of the longitudinal direction of the bootie and the
circumferential direction of the bootie.
19. Footwear (2) according to any of the preceding claims, wherein
the one-piece, seamless functional layer comprises at least one of
ePTFE, PU, PP, PES, and high density PE.
20. Footwear (2) according to any of the preceding claims, wherein
the at least one textile layer is one of knitted, woven or
non-woven textile.
21. Footwear (2) according to any of the preceding claims, wherein
the outer construction (40, 42) comprises a breathable outer
material.
22. Footwear (2) according to any of the preceding claims, wherein
the sole (6) has water vapor discharge holes towards a lateral side
of the sole and/or towards a bottom surface of the sole, with water
vapor from the foot being discharged through the bootie (50),
through a sole interior, and through the water vapor discharge
holes to an outside environment of the footwear.
23. Bootie (50) for use in footwear according to any of the
preceding claims, wherein the bootie is made with a waterproof,
breathable laminate, the waterproof, breathable laminate comprising
a one-piece functional layer and at least one textile layer, and
wherein the bootie has elasticity in a circumferential direction of
the bootie.
24. Method for producing footwear (2) comprising an upper assembly
(4) having an outer construction (40, 42) and a sole (6), the
method comprising the steps of: providing a bootie (50) made with a
waterproof, breathable laminate (51), the waterproof, breathable
laminate (51) comprising a one-piece functional layer (54) and at
least one textile layer (56, 58), wherein the bootie has elasticity
in a circumferential direction of the bootie, and arranging the
bootie (50) in an inner space of the upper assembly (4) and the
sole (6), with the bootie being fixed in position in a toe region
(90) of the footwear and fixed in position in a heel region (96) of
the footwear and with the bootie not being attached to the outer
construction on an upper side a midfoot portion (92) of the
bootie.
25. Method according to claim 24, wherein the one-piece functional
layer (54) is a seamless, one-piece functional layer, with the step
of providing the bootie (50) comprising the step of expanding the
seamless, one-piece functional layer over a last.
Description
[0001] The present invention is in the field of footwear. In
particular, the present invention is in the field of waterproof,
breathable footwear, providing an all around waterproof structure
around the wearer's foot.
[0002] Waterproof shoes have been known for a long time. In recent
years, waterproof and breathable shoes have been developed that
provide for an all-around waterproof structure around the wearer's
foot, but at the same time provide breathability, such that
moisture and sweat from the wearer's foot can escape from the
interior of the shoe. Such shoes commonly have an arrangement of
various waterproof and breathable functional layers, also referred
to as waterproof and breathable membranes, extending around the
inner space of the shoe. For example, a lower functional layer
underneath the wearer's foot may be combined with an upper
functional layer on top and to the sides of the wearer's foot, with
the two functional layers being joined along their periphery by a
sewn seam. In this way, a waterproof and breathable bag around a
wearer's foot may be provided. Previous approaches for waterproof
and breathable footwear have not been fully satisfactory in terms
of user comfort.
[0003] Accordingly, it would be beneficial to provide footwear that
allows for an improved comfort to the wearer, while maintaining
waterproofness and breathability.
[0004] Exemplary embodiments of the invention include footwear
comprising an upper assembly having an outer construction and a
bootie, and a sole attached to the upper assembly. The bootie is
made with a waterproof, breathable laminate, the waterproof,
breathable laminate comprising a one-piece functional layer and at
least one textile layer. The bootie has elasticity in a
circumferential direction of the bootie, the bootie is fixed in
position in a toe region of the footwear and fixed in position in a
heel region of the footwear, and the bootie is not attached to the
outer construction on an upper side of a midfoot portion of the
bootie.
[0005] Exemplary embodiments of the invention allow for an improved
comfort for the user when wearing the footwear. In particular, the
provision of the bootie with a one-piece functional layer and
elasticity in the circumferential direction of the bootie, together
with the freedom to move with respect to the outer construction on
the upper side of the midfoot portion of the bootie, provides for
an optimized compromise between a stable and non-disturbing feel of
the footwear that also provides a perceived high level of freedom
to move within the footwear. The fixing of the bootie in position
in the toe region and the heel region of the footwear and the
elasticity in the circumferential direction of the bootie provide
for a well-defined stance of the user within the footwear and for
an overall stable feel due to the elastic tightening of the bootie
around the wearer's foot. While the attachment in the front and the
back of the shoe and the elasticity in the circumferential
direction of the bootie provide for support and a sense of stance
safety to the wearer, the non-attachment to the outer construction
on the upper side of the midfoot portion of the bootie provides for
a high level of perceived freedom to move. It has been found that
the potential for relative motion between the bootie and the outer
construction on the upper side of the midfoot portion of the bootie
leads to a high level of comfort and a feeling of not being
confined by the footwear, while not compromising the wearer's
feeling of stability. The described combination of
attachment/non-attachment and the elasticity of the bootie provides
for an optimized compromise between stability and freedom to move,
thus increasing the wearer's comfort. The bootie having a
waterproof, breathable laminate with a one-piece functional layer
enhances all of the described effects. The one-piece nature makes
the elasticity of the bootie immediately present around the
wearer's foot, making the bootie feel stable and comfortable to the
user. Also, the one-piece nature, leading to a bootie with at most
one seam, leads to a very low or even entirely eliminated
impairment of comfort, as will be described below.
[0006] The term bootie refers to a sock-like structure that encases
the foot of the wearer, when inserted into the footwear. The bootie
is generally arranged in the space between the outer construction
of the upper assembly and the sole, i.e. in the inner space of the
shoe. The bootie may also extend out of the inner space of the shoe
at the collar region of the upper assembly. In other words, the
bootie may extend upwards from the outer construction of the upper
assembly. The bootie is made with a waterproof, breathable
laminate. In this way, the bootie provides a waterproof and
breathable sock-like structure all around the wearer's foot, with
the exception of at most one seam, as will be discussed below. This
waterproof and breathable bootie construction allows for the
discharge of water vapor from the wearer's foot through the bootie
and to the outside of the footwear via the outer construction
and/or the sole.
[0007] The waterproof, breathable laminate comprises a one-piece
functional layer and at least one textile layer. The one-piece
functional layer and the at least one textile layer may be
substantially co-extensive. The term at least one textile layer
intends to state that the one-piece functional layer may be
provided with a textile layer on one side thereof or with a textile
layer on each side thereof, i.e. with two textile layers. It is
also possible that more than one textile layer is provided on one
side or on both sides. In addition, each textile layer may be made
up of multiple textile pieces. For example, the waterproof,
breathable laminate may comprise a one-piece functional layer and
one textile layer on one side of the functional layer, with the one
textile layer being made up of multiple textile pieces that are
sewn together. In other words, the one-piece functional layer may
be provided with one or more textile layers that are made up from
originally separate textile pieces.
[0008] With the functional layer being a one-piece structure, the
waterproof, breathable laminate is also considered a one-piece
structure. This is irrespective of whether the textile layer is
made of originally separate textile pieces or not. In case the
textile layer is made of originally separate textile pieces, a
one-piece laminate structure is present, at least at the point
where the laminate is formed from the one-piece functional layer
and the multiple textile pieces. Hence, the bootie is made from one
continuous waterproof, breathable laminate and is also considered a
one-piece structure. In particular, the bootie is made from a
continuous waterproof, breathable laminate, which may be shaped to
inherently have the form of a bootie or which may be cut, folded
and sewn or glued together to form a bootie.
[0009] An exemplary construction method for a bootie in accordance
with the former case is as follows. A textile layer may be formed
from a plurality of textile pieces. The plurality of textile pieces
may be sized and sewn together in such a way that a sock-like
textile layer is formed. The sock-like textile layer may be placed
on a last, and a functional layer may be stretched over the last
and brought into contact with the sock-like textile layer. The
functional layer is adhered to the textile layer and the
waterproof, breathable laminate is thus formed. This waterproof,
breathable laminate has the inherent shape of a bootie. Both the
waterproof, breathable laminate and the bootie are considered
seamless. The seams between the originally separate textile pieces,
if present, are considered to be seams of a precursor product and
are not considered seams of the laminate of the bootie. It is also
possible that one or more of the at least one textile layer are
seamless as well.
[0010] In the alternative of the cut, folded and sewn/glued
laminate forming the bootie, a substantially flat waterproof,
breathable laminate is provided, for example having a one-piece
functional layer and a textile layer on one side, potentially made
from originally separate textile pieces. The laminate is cut in
such a shape that, upon folding the laminate, a sock-like shape is
formed. The edges of the laminate are then sewn or glued together,
such that the sock-like shape is retained.
[0011] The waterproof, breathable laminate may be a two-layer
laminate consisting of the functional layer and a textile layer.
The waterproof, breathable laminate may also be a three-layer
laminate, with the functional layer being sandwiched between a
first textile layer and a second textile layer on opposite sides of
the functional layer. The waterproof, breathable laminate may also
comprise one or more further layers, such as an additional
water-stopping layer, keeping water off the functional layer and
thus ensuring breathability thereof. The term functional layer is a
commonly used term in the art of footwear and refers to a layer
combining waterproof and breathable characteristics. Alternatively,
a functional layer is also often referred to as a waterproof,
breathable membrane.
[0012] The functional layer may include or may be a breathable and
waterproof membrane. The membrane may be selected from
polyurethane, polyester, polyether, polyamide, polyacrylate,
copolyether ester and copolyether amides, as well as other suitable
thermoplastic and elastomeric films. In a particular embodiment,
the waterproof, breathable membrane may be made of a fluoropolymer,
particularly made of microporous expanded polytetrafluoroethylene
(ePTFE). The microporous polytetrafluoroethylene membrane is a
membrane of expanded polytetrafluoroethylene as taught in U.S. Pat.
Nos. 3,953,566 and 4,187,390, to Gore. Such membranes of expanded
polytetrafluoroethylene are present in commercially available
laminates from W. L. Gore and Associates, Inc., Elkton, Md., under
the tradename GORE-TEX.RTM. fabric. The breathable and waterproof
functional layer may be composed of a polyurethane coated
microporous expanded polytetrafluoroethylene membrane made
substantially according to the teachings of U.S. Pat. No. 4,194,041
and U.S. Pat. No. 4,942,214, assigned to W. L. Gore and Associates,
Inc, in Elkton, Md.
[0013] The bootie is elastic in the circumferential direction
thereof. In other words, when the wearer inserts a foot into the
footwear, the bootie is able to stretch and to expand elastically
in order to make room for the foot of the wearer. In this process,
the bootie conforms to the foot of the wearer, it is therefore also
referred to as a conformable bootie. The bootie being elastic means
that it exerts a force against the wearer's foot upon insertion
thereof. In other words, the elasticity builds up a force that
forces the bootie towards its shape before insertion of the
wearer's foot. This force provides for a recovery of the bootie
towards its previous shape after exertion of the wearer's foot. The
elastic nature of the bootie may be achieved in any suitable way.
Particular examples of producing elastic laminates are given in WO
95/32093 A1, the contents of which is incorporated herein by
reference in its entirety.
[0014] The bootie is elastic in a circumferential direction
thereof. This expression does not require the bootie to be elastic
in the circumferential direction along its entire length. The
bootie is elastic along a substantial part of its length. In
particular, the bootie may be elastic in the circumferential
direction in the midfoot portion. It is, however, also possible
that the bootie is elastic in the circumferential direction along
its entire length.
[0015] The bootie is arranged underneath and towards the inside of
the outer construction of the upper assembly. The term outer
construction generally refers to that part of the shoe that is seen
from the outside of the shoe on top of the sole. It also includes
the non-visible extensions of these materials, e.g. a lasted upper
material. The outer construction further includes additional
structures above and to the sides of the foot, even if they are not
visible from the outside, e.g. a hidden tongue.
[0016] The bootie is not attached to the outer construction on the
upper side of the mid-foot portion of the bootie. In other words,
the bootie is free of attachments/attachment points with respect to
the outer construction on the upper side of the midfoot portion. In
yet other words, the bootie is free to move with respect to the
outer construction on its upper side in the midfoot portion. In
particular, it is possible that the bootie is not attached to the
midfoot portion of the outer construction of the upper
assembly.
[0017] The laminate is waterproof and breathable. Being made with
the waterproof, breathable laminate, the bootie is also waterproof
and breathable. In case the bootie has a seam connecting the edges
of the functional layer to yield the sock-like shape, the seam
region is made waterproof. For example, a waterproof seam tape may
be arranged along the seam region. With the bootie being waterproof
and breathable, the footwear as a whole may also be referred to as
a waterproof, breathable footwear. The bootie forms a waterproof
bag around the wearer's foot, lending waterproofness to the
footwear as a whole. The footwear is breathable, because the outer
construction has a breathable outer material and/or the sole is
breathable. The sole may be made from a breathable material and/or
may have a breathable structure, as will be explained below.
[0018] The terms upper assembly and sole generally indicate
structures that are manufactured separately or subsequently in
accordance with traditional shoe manufacturing, as described
herein. However, with advances in shoe manufacturing, it is also
possible that the upper assembly and the sole are formed as an
integrated structure. For example, the combination of the upper
assembly and the sole may be manufactured as a 3D knit or in
accordance with another 3D manufacturing process. Such integrated
structures comprising both the upper assembly and the sole are also
encompassed by the footwear as claimed herein. It is also possible
that the upper assembly comprises an integrated structure around
the wearer's foot, which has the breathable outer material and the
insole made as one integrated structure and into which the bootie
is inserted.
[0019] According to a further embodiment, an air gap is present
between the bootie and the outer construction on the upper side of
the midfoot portion of the bootie. The air gap is present when no
foot is inserted into the footwear. It is further possible that the
air gap is also still present when a foot is inserted into the
footwear. The air gap between the bootie and the outer construction
allows for an expansion of the bootie on the upper side of the
midfoot portion without any resistance by another material. In this
way, the upper side of the midfoot portion of the bootie is
particularly free to move, thus providing a lot of comfort and
perceived freedom to move to the wearer.
[0020] According to a further embodiment, a compressible material
layer is present between the bootie and the outer construction on
the upper side of the midfoot portion of the bootie. A compressible
material may also provide for freedom to move, while at the same
time providing a somewhat stronger frame of stability for the foot
than an air gap. It is also possible to have both a compressible
material and an air gap present between the bootie and the outer
construction on the upper side of the midfoot portion of the
bootie. The compressible material may be either attached to the
upper side of the bootie or to the outer construction. However, the
compressible material may not be attached to both the outer
construction and the bootie, in order for the relative movement of
the bootie with respect to the outer construction to not be
compromised.
[0021] According to a further embodiment, the bootie and the outer
construction are jointly extendable on the upper side of the
midfoot portion of the bootie. As discussed above, the
circumferential elasticity of the bootie allows for an expansion
thereof upon the insertion of the wearer's foot. With the bootie
and the outer construction being jointly extendable, the two
structures may jointly provide support for the wearer's foot. The
potential for relative movement of the two structures with respect
to each other is ensured due to the non-attachment on the upper
side of the midfoot portion.
[0022] According to a further embodiment, the midfoot portion
extends along at least 80%, in particular along at least 90%,
further in particular along 100%, of the length from a foot instep
portion of the upper assembly corresponding to a navicular area of
a foot forward to a ball portion of the upper assembly
corresponding to metatarsal point 1--phalanges joint of the foot.
In other words, the upper side of the bootie is not attached to the
outer construction--at least on the upper side of the bootie--along
at least 80%, in particular along at least 90%, further in
particular along 100%, of the length from a foot instep portion of
the upper assembly corresponding to a navicular area of a foot
forward to a ball portion of the upper assembly corresponding to
metatarsal point 1--phalanges joint of the foot. The navicular area
of the foot and the metatarsal point 1--phalanges joint of the foot
are well-defined anatomical portions of the human foot. They are in
particular well-defined for a given foot size, which allows for a
derivation of the corresponding foot instep portion and the
corresponding ball portion of the upper assembly for a given shoe
size. It has been found that a high-level of perceived freedom to
move and a high level of comfort can be achieved by allowing for
relative movement of the bootie with respect to the outer
construction in a very large part or the entire portion of the
upper side of the foot between the navicular area and the
metatarsal point 1--phalanges joint.
[0023] According to a further embodiment, the midfoot portion
extends along at least 80%, in particular at least along at least
90%, further in particular along 100%, of the length from an upper
tongue portion of the outer construction forward to a toe box area
of the outer construction. In other words, the bootie is not
attached to the outer construction--at least on the upper side of
the bootie--along at least 80%, in particular along at least 90%,
further in particular along 100%, of the length from an upper
tongue portion of the outer construction forward to a toe box area.
In this way, the attachment-free portion of the upper side of the
bootie may be maximized in terms of the underlying shoe
construction. In particular, the area between the upper tongue
portion, where an attachment of the bootie to a collar region of
the outer construction may be present, to the toe box area, where a
further attachment between the bootie and the remaining shoe
construction takes place, can be kept free of attachment points,
thus maximising the freedom to move on the upper side of the bootie
in the midfoot portion for the given shoe construction. In footwear
technology, the toe box area is a well-defined portion of the shoe,
where the toe portion of the foot is embedded into the particular
footwear construction.
[0024] According to a further embodiment, the bootie is not
attached to the outer construction around at least 50%, in
particular around at least 60%, further in particular around at
least 65%, of the circumference of the bootie in the midfoot
portion. In other words, at least 50%, in particular at least 60%,
further in particular at least 65%, of the circumference of the
bootie are not attached to the outer construction. In yet other
words, at least 50%, in particular at least 60%, further in
particular at least 65%, of the circumference of the bootie are
free to move within the footwear, with the free portion of the
circumference forming an upper part of the bootie. The given values
relate to all cross-sections along the midfoot portion of the
bootie. In this way, a large un-attached area of the bootie is
provided in the midfoot portion, such that the freedom to move is
felt particularly well by the wearer. In particular, the upper side
of the midfoot portion of the bootie, i.e. the un-attached part of
the midfoot portion of the bootie, may have an extension of between
50% and 90%, in particular of between 60% and 85%, further in
particular of between 65% and 85%, of a midfoot circumference of
the bootie. Accordingly, a small portion, in particular between 10%
and 15%, of the midfoot circumference of the bootie may be used for
attachments. This small portion of attachment is provided on the
lower side of the midfoot portion of the bootie, i.e. towards the
sole or insole. It is stressed that the bootie may also be
non-attached around its entire circumference in the midfoot
portion.
[0025] According to a further embodiment, the one-piece functional
layer is seamless on the upper side of the midfoot portion of the
bootie. A one-piece functional layer may be entirely seamless, as
has been described above will be described further below, or may be
made from one single piece of functional layer/laminate, which is
brought into a bootie form by sewing/glueing its edges together. In
both cases, the bootie is considered a one-piece bootie,
irrespective of the number of textile pieces used for forming a
textile layer, as has been described above. In the former case, the
bootie is considered seamless. In the latter case, the bootie is
considered to have a seam. This seam may be arranged in such a way
that the upper side of the midfoot portion of the bootie is free of
said seam, i.e. seamless. In a simplified illustrative example, a
one-piece bootie with one seam can be visualized as a particular
cut of a laminate, wrapped around a last and sewn together at its
edges. The cut of the laminate has such a shape that it fully
covers the last. While the resulting seam may have various partial
seams for adapting the laminate to the complex shape of a human
foot, it is still considered a single seam holding the edges of the
one-piece functional layer/laminate together. The waterproof nature
of the bootie may be ensured by using a waterproof seam tape along
said described seam. The feature of the one-piece functional layer
being seamless on the upper side of the midfoot portion of the
bootie means that said described seam, if present, does not extend
in the region of the upper side of the midfoot portion of the
bootie. Rather, the bootie is arranged such that the seam, if
present, extends along the lower side of the bootie in the midfoot
portion. In a particular embodiment, the one-piece functional layer
is seamless on the whole upper side of the bootie. Further, it is
explicitly pointed out that, with the one-piece functional layer
being seamless on the upper side of the midfoot portion of the
bootie, the whole bootie, including all its layers, may be seamless
on the upper side of the midfoot portion of the bootie. With no
seams being present on the upper side of the midfoot portion of the
bootie, the upper portion of the foot does not rub against any
seams, adding to the perceived comfort for the user.
[0026] According to a further embodiment, the one-piece functional
layer is a seamless, one-piece functional layer. As described
above, with the functional layer being a seamless, one-piece
functional layer, the bootie is also considered a seamless,
one-piece bootie, irrespective of the number of textile pieces used
for making the waterproof, breathable laminate. In particular, the
functional layer may be inherently shaped in the form of a bootie,
e.g. by expanding the same over a last and a textile layer, thus
having no seams. In other words, the functional layer/laminate may
be manufactured to have the shape of a bootie, i.e. to have a
sock-like shape, without the need for attaching different parts of
the functional layer/laminate to each other. In particular, there
is no need for sewing or glueing edges of the functional
layer/laminate together in this case. Such bootie-shaped waterproof
and breathable functional layer constructions are per se known,
e.g. from WO 2015/123482 A1, the contents of which is incorporated
herein in its entirety. In particular, it is known how the
functional layer can be transformed from a plane layer into a
bootie-shaped structure. For the details of said manufacturing
process, reference is made to WO 2015/123482 A1. The provision of
the seamless one-piece functional layer, and thus of the seamless,
one-piece bootie, provides for a particularly high level of comfort
to the wearer, because no seams interfere with the all-around
feeling of stability, conformity and freedom to move.
[0027] According to a further embodiment, the upper assembly
comprises an assembly insole and the bootie is attached to at least
one of the outer construction and the assembly insole in the toe
area and to at least one of the outer construction and the assembly
insole in the heel area. The assembly insole is arranged below the
bootie. The outer construction may be attached to the assembly
insole in an outer circumferential portion of the assembly insole,
e.g. an upper material of the outer construction may be lasted onto
the assembly insole. The assembly insole may be breathable for
water vapor to be discharged through the assembly insole and on to
the sole of the footwear. However, it is also possible that the
assembly insole is not made from a breathable material. In both the
toe area and the heel area of the footwear, the bootie may be
attached to one of the outer construction and the assembly insole
or to both the outer construction and the assembly insole.
[0028] According to a further embodiment, the bootie is not
attached to the assembly insole on a lower side of the midfoot
portion of the bootie. In this way, the bootie is entirely
un-attached in its midfoot portion. In this way, the freedom to
move with respect to the surrounding shoe construction is maximized
for the wearer's foot in the midfoot portion. The feeling of
stability, provided by the elastic bootie, is paired with a maximum
flexibility for the midfoot portion of the foot.
[0029] It is pointed out that it is also possible that the bootie
is attached to the assembly insole on the lower side of the midfoot
portion of the bootie. In particular, the bootie may be attached to
the assembly insole around at most 50%, in particular around at
most 40%, further in particular around at most 30%, further in
particular around at most 20%, further in particular around at most
10%, of the midfoot circumference of the bootie. With the given
values, a desired compromise between stability and flexibility can
be achieved, while allowing for a well-defined positional
arrangement of the bootie within the footwear by providing some
form of attachment in the midfoot portion. Again, the given values
relate to all cross-sections of the midfoot portion of the
bootie.
[0030] According to a further embodiment, the bootie forms an
outermost lower part of the upper assembly towards the sole of the
footwear and the bootie is attached to at least one of the outer
construction of the upper assembly and the sole in the toe area and
to at least one of the outer construction of the upper assembly and
the sole in the heel area. The bootie forming the outermost lower
part of the upper assembly means that no separate assembly insole
is provided underneath the bootie. In particular, the lower portion
of the bootie may assume the function of an assembly insole,
providing stability of the upper assembly during production and
providing a well-defined lower part of the upper assembly for
attachment to the sole. In this case, the sole may be directly
attached to the bootie. It is pointed out that, both in the toe
area and the heel area, the bootie may be attached to one of the
outer construction and the sole or to both of these structures.
[0031] According to a further embodiment, the bootie is not
attached to the sole on a lower side of the midfoot portion of the
bootie. In this way, maximum freedom to move and flexibility is
provided for the bootie in the midfoot portion of the footwear. It
is pointed out that the bootie may also be attached to the lower
side of the midfoot portion of the bootie. In particular, the sole
may be attached to the lower side of the bootie along the same
portions of the bootie circumference as described above with
respect to the assembly insole. In the particular case of an
injected sole, the sole may be directly injected on and formed onto
the bootie and the outer construction of the upper assembly. In
that process, the sole may form a strong attachment to the bootie,
while the attachment area can be closely controlled in the
manufacturing process and can be kept small for a large degree of
freedom to move for the bootie.
[0032] According to a further embodiment, the bootie is attached to
the outer construction of the upper assembly in a collar region of
the footwear. In particular, the bootie may be attached to the
outer construction around a shoe instep portion, i.e. around the
opening through which the wearer inserts his/her foot. In this way,
a third attachment region besides the toe region and the heel
region is provided, such that the bootie is strongly fixed in
position with respect to the remainer of the footwear, while
maintaining freedom to move in the midfoot portion, as is highly
desirable for user comfort, as discussed above.
[0033] According to a further embodiment, the bootie has a midfoot
circumference in the midfoot portion that is between 60% and 99%,
in particular between 70% and 95%, further in particular between
80% and 90% of a foot circumference in the midfoot portion. In this
way, the bootie expands upon foot insertion and provides a pleasant
feel of stability and comfort due to its elasticity, i.e. due to
its pressure exertion on the foot. With the given midfoot
circumference values of the bootie, a particularly pleasant
compromise between the comfortable and stable fit of slight back
pressure and sufficient freedom to move without feeling constrained
by the back pressure can be achieved. The foot circumference is the
circumference of a typical foot for the given shoe size. The
typical foot is a non-deformed foot, i.e. a foot without abnormal
deformations. The foot circumference may thus be defined in
accordance with the anatomical properties of a foot, i.e. in
accordance with the properties as given in medicine text book. It
is also possible to define the foot circumference as a mean or
medium value for a relevant set of measured feet
circumferences.
[0034] According to a further embodiment, the bootie has elasticity
in a longitudinal direction of the bootie. In this way, the bootie
has elasticity both in the circumferential direction of the bootie
and the longitudinal direction of the bootie, thus providing the
feeling of stability and comfort to the wearer in an enhanced
manner. When having longitudinal elasticity in addition to
circumferential elasticity, the bootie is also said to have biaxial
elasticity.
[0035] According to a further embodiment, the bootie has a
longitudinal elasticity of at most 15 N/cm, in particular of at
most 5 N/cm, at 10% elongation in the longitudinal direction of the
bootie. The elasticity is measured as the force that is required to
keep the sample at 10% elongation, with the cm value referring to
the width of the test sample of the bootie. The elasticity is
measured in accordance with DIN EN 14704-1, in the version of July
2005. The given values have been found to provide a bootie with a
particularly comfortable fit, applying some force onto the foot for
a stable and comfortable fit, while avoiding a constrained feeling
of the foot due to too much pressure. In a particular embodiment,
the bootie has a longitudinal elasticity of at least 0.5 N/cm at
10% elongation in the longitudinal direction of the bootie. In this
way, a minimum amount of pressure for stability and a conformable
fit may be achieved. The elasticity of the bootie may for example
be regulated by using textiles for the at least one textile layer
that have the desired retractive force.
[0036] According to a further embodiment, the bootie has a
circumferential elasticity of at most 15 N/cm, in particular of at
most 5 N/cm, at 30% elongation in the circumferential direction of
the bootie. The elongation in the circumferential direction is
defined in terms of a bootie sample, e.g. of the bootie material
when the bootie is cut open. In other words, the elongation value
is not defined for the bootie, as inserted into the footwear
described herein, because an extension thereof in the
circumferential direction would require stretching two layers of
the bootie at the same time. The given elasticity values have been
found to provide a very comfortable compromise between
circumferential pressure on the foot, conveying stability and a
comfortable fit, while keeping the elastic pressure at values that
are not perceived as disturbing. In particular, the bootie may have
a circumferential elasticity of at least 0.5 N/cm at 30% elongation
in the circumferential direction of the bootie. In this way, a
comfortable minimum back pressure onto the wearer's foot may be
achieved. The elasticity of the bootie may for example be regulated
by using textiles for the at least one textile layer that have the
desired retractive force.
[0037] According to a further embodiment, the bootie has an elastic
recovery of at least 75% in at least one of the longitudinal
direction of the bootie and the circumferential direction of the
bootie. In particular, the bootie has an elastic recovery of at
least 75% in both the longitudinal direction and the
circumferential direction of the bootie. The elastic recovery may
again be measured according to DIN EN 14704-1, in the version of
July 2005. With such elastic recovery, the comfortable fit of the
bootie and, thus, of the footwear may be upheld over an extended
period of time. The bootie may return nearly or entirely to its
original shape after use, such that the wearer experiences the same
or nearly the same comfortable fit, when using the footwear the
next time.
[0038] According to a further embodiment, the one-piece functional
layer comprises at least one of ePTFE (expended
polytetrafluoroethylene), PU (polyurethane), PP (polypropylene),
PES (polyester) and high density PE (high density polyethylene).
All of the given materials are suitable for forming a waterproof
and breathable functional layer and for achieving the elasticity
described herein before. In a particular embodiment, the functional
layer is an ePTFE membrane. It is also possible that the
waterproof, breathable laminate has layers of different ones of the
mentioned materials. For example, the waterproof, breathable
laminate may have an ePTFE layer as well as a PU layer, with the PU
layer keeping water from the ePTFE layer and thus ensuring that the
breathability of the ePTFE layer is not compromised by water.
[0039] According to a further embodiment, the at least one textile
layer is one of knitted, woven or non-woven textile. In particular,
each of the at least one textile layer may be one of knitted, woven
or non-woven textile. Knitted, woven or non-woven textiles are
particularly suitable for the bootie of the footwear described
herein, because these materials may be manufactured in a
particularly beneficial elastic/stretchable manner. In this way,
they are able to effectively contribute to the elasticity of the
bootie. In these and other kinds of textiles that may be used, the
fibers may be elastic, such as those made from polyamide, e.g.
nylon, or polyurethane, e.g. elastance or spandex, sold inter alia
under the trade mark Lycra, or rubber. It is not required that all
fibers are elastic to make the textile stretchable. It is possible
to use yarns made of different fibers, e.g. 20% polyurethane and
80% polyamide. Stretchable textiles may also be provided by
providing suitable fiber structures, e.g. in a knit, or by
texturing, e.g. crimping, the fibers in the textile.
[0040] According to a further embodiment, the outer construction
comprises a breathable outer material. In a particular embodiment,
the outer construction may essentially consist of a breathable
outer material. In this way, the bootie and the breathable outer
material may provide for a water vapor discharge path to the
outside environment with a very low number of layers. In this way,
the water vapor discharge may be achieved in a particularly
efficient manner.
[0041] According to a further embodiment, the sole has water vapor
discharge holes towards a lateral side of the sole and/or towards
the bottom surface of the sole, with water vapor from the foot
being discharged through the bootie through a sole interior and
through the water vapor discharge holes to an outside environment
of the footwear. In this way, water vapor discharge may be achieved
though the sole, providing a short and effective water vapor
discharge path from the underside of the foot to the outside
environment of the footwear. The sole as a whole can thus be seen
as a breathable sole, irrespective of whether or not the sole is
manufactured from breathable material. The water vapor discharge
through the sole may be in addition to the water vapor discharge
through the outer construction of the upper assembly, in particular
in addition to the water vapor discharge through a breathable outer
material of the upper assembly.
[0042] Exemplary embodiments of the invention further include a
bootie for use in footwear, as described in any of the embodiments
above, wherein the bootie is made with a waterproof, breathable
laminate, the waterproof, breathable laminate comprising a
one-piece functional layer and at least one textile layer, and
wherein the bootie has elasticity in circumferential direction of
the bootie. The modifications, additional features, and effects,
described above with respect to the footwear, apply to the bootie
for use in said footwear in analogous manner.
[0043] Exemplary embodiments of the invention further include a
method for producing footwear comprising an upper assembly having
an outer construction and a sole, the method comprising the steps
of providing a bootie made with a waterproof, breathable laminate,
the waterproof, breathable laminate comprising a one-piece
functional layer and at least one textile layer, wherein the bootie
has elasticity in a circumferential direction of the bootie; and
arranging the bootie in an inner space of the upper assembly and
the sole, with the bootie being fixed in position in a toe region
of the footwear and fixed in position in a heel region of the
footwear and with the bootie not being attached to the outer
construction on an upper side a midfoot portion of the bootie. The
modifications, additional features and effects, described above
with respect to the footwear, apply to the method for producing
footwear in an analogous manner. The term inner space of the upper
assembly and the sole indicates the space of the footwear that is
intended for receiving the foot. It is denoted the inner space of
the upper assembly and the sole, because both the upper assembly
and the sole are arranged around this space. It is, however,
possible that the upper assembly encases this whole space, with the
sole being separated from this space by a portion of the upper
assembly, such as an assembly insole. Such a construction is
encompassed by the term inner space of the upper assembly and the
sole. The term arranging the bootie in the inner space of the upper
assembly and the sole encompasses both an insertion of the bootie
into said inner space and a creation of the outer structure of the
footwear around the bootie.
[0044] According to a further embodiment, the one-piece functional
layer is a seamless, one-piece functional layer, with the step of
providing the bootie comprising the step of expanding the seamless,
one-piece functional layer over a last.
[0045] Further exemplary embodiments of the invention are described
with respect to the accompanying figures, wherein:
[0046] FIG. 1 shows footwear in accordance with an exemplary
embodiment of the invention, depicted in a longitudinal sectional
view;
[0047] FIG. 2 shows the footwear of FIG. 1, depicted in a
transverse sectional view;
[0048] FIG. 3 shows footwear in accordance with another exemplary
embodiment of the invention, depicted in a longitudinal sectional
view;
[0049] FIG. 4 shows the footwear of FIG. 3, depicted in a
transverse sectional view;
[0050] FIG. 5 shows the anatomy of human feet in a top view;
[0051] FIG. 6 shows footwear in accordance with a further exemplary
embodiment of the invention, depicted in a longitudinal sectional
view;
[0052] FIG. 7 shows footwear in accordance with yet another
exemplary embodiment of the invention, depicted in a longitudinal
sectional view;
[0053] FIG. 8 shows exemplary embodiments of waterproof, breathable
laminates, to be used in footwear in accordance with exemplary
embodiments of the invention, in cross-sectional views.
[0054] FIG. 1 shows footwear 2 in accordance with an exemplary
embodiment of the invention, depicted in a longitudinal sectional
view, with the cross-sectional plane of FIG. 1 running
substantially through the center of the footwear 2. In the
exemplary embodiment of FIG. 1, the footwear 2 is a boot, also
referred to as a boot-type shoe, whose upper assembly extends
upwards over the wearer's ankle. The depicted boot-type shoe is
exemplary in nature, and other types of footwear/shoes, in
particular low shoes, may be constructed in an analogous
manner.
[0055] The shoe 2 comprises an upper assembly 4 and a sole 6. The
shoe is of a lasted construction. The upper assembly 4 comprises a
breathable outer material 40, such as leather, suede, textile or
any other suitable material, and an assembly insole 44. The
breathable outer material 40 is perimetrically lasted onto the
assembly insole 44 from the bottom. In particular, the breathable
outer material 40 is glued onto the bottom of the assembly insole
44 around its perimeter with a lasting glue.
[0056] The upper assembly 4 further comprises a tongue 42. In the
exemplary embodiment of FIG. 1, the tongue 42 is an originally
separate structure from the breathable outer material 40 and is
attached thereto, e.g. via sewing or gluing. It is also possible
that the tongue 42 and the breathable outer material 44 are
integrally formed from a continuous piece of material. The
breathable outer material 40 and the tongue 42 form an outer
construction of the footwear 2. In general, the outer construction
of the footwear 2 may be a single integrated structure, such as a
three-dimensional knit, or may be assembled from various originally
separate pieces of a breathable material, as is for example common
in leather shoes/boots.
[0057] In the exemplary embodiment of FIG. 1, the sole 6 is a solid
structure of a non-breathable material, e.g. a solid plastic
structure. In the exemplary embodiment of FIG. 1, the sole 6 is
injected onto the lower side of the upper assembly 4, forming a
strong bond to the lasted portion of the outer material 40 and to
the assembly insole 44 in the process of injection. The sole 6 may
also be glued to the lower portion of the upper assembly 4. It is
further possible that the sole 6 is made from inherently breathable
materials, such as leather, and/or that the sole has a structure
that allows for breathability through the sole, as will be
described below.
[0058] The upper assembly 4 further includes a bootie 50. The
bootie 50 is a sock-like structure that is inserted into the space
between the outer construction of the upper assembly, comprising
the breathable outer material 40 and the tongue 42, and the
assembly insole 44. Being arranged in the interior space of the
upper assembly 4, the bootie 50 may also be referred to as a shoe
insert. In the exemplary embodiment of FIG. 1, the upper end of the
bootie 50 is at the same height as the upper end of the outer
material 40. It is also possible that the upper end of the bootie
50 ends below the upper end of the outer material 40 or extends
above the upper end of the outer material 40.
[0059] The bootie 50 is made with a waterproof, breathable
laminate. In particular, the exemplary bootie 50 of FIG. 1 is a
waterproof, breathable laminate, shaped into the sock-like form.
The waterproof, breathable laminate comprises a one-piece, seamless
functional layer, which is manufactured by stretching the
functional layer over a shoe last. In addition, the waterproof,
breathable laminate comprises two textile layers arranged on
opposite sides of the functional layer and adhered to the
functional layer. Accordingly, the bootie 50 is made with a
three-layered waterproof, breathable laminate.
[0060] The footwear 2 has a forefoot portion 90, a midfoot portion
92, and a rearfoot portion 94. The forefoot portion 90, the midfoot
portion 92, and the rearfoot portion 94 are separated by dashed
lines in FIG. 1. The forefoot portion 90 may also be referred to as
a toe region of the footwear. The rearfoot portion 94 comprises a
heel region 96 and collar region 98. Given the fairly low
construction of the boot 2 of FIG. 1, the rearfoot portion 94
consists of the heel region 96 and the collar region 98 in the
exemplary embodiment of FIG. 1. However, it is also possible that
further regions are interposed between the heel region 96 and the
collar region 98 in other constructions.
[0061] The bootie 50 is attached to the breathable outer material
40, to the tongue 42, and to the assembly insole 44 in the forefoot
portion/toe region 90, in the heel region 96, and the collar region
98. In particular, the bootie 50 is fixed in position by various
glue portions, as will be described below. The bootie 50 is
attached to the breathable outer material 40 and the tongue 42 in
the collar region 98 via a first glue portion 70, which surrounds
the circumference of the bootie 50. The bootie 50 is attached to
the outer material 40 in the heel region 96 via a second glue
portion 72. The second glue portion 72 extends around a part of the
circumference of the bootie 50, e.g. in a substantially
semi-circular manner. The bootie 50 is attached to the assembly
insole 44 in the heel region 96 via a third glue portion 74. The
third glue portion 74 has an extension corresponding substantially
to the stance area of the heel of the wearer's foot. The bootie 50
is further attached to the assembly insole 44 in the forefoot
portion/toe region 90 via a forth glue portion 76. Further, the
bootie 50 is attached to the breathable outer material 40 in the
forefoot portion/toe region 90 via a fifth glue portion 78. The
forth glue portion 76 and the fifth glue portion 78 extend
substantially across the entire width of the upper assembly 4 in
the forefoot portion 90. It is understood that the arrangement of
the glue portions is exemplary in nature and that the positional
fixation of the bootie in the toe region, the heel region, and the
collar region may be achieved via other glue arrangements as
well.
[0062] The bootie 50 is free of attachments to the remainder of the
upper assembly 4 in the midfoot portion 92. In particular, in the
exemplary embodiment of FIG. 1, the bootie 50 is neither attached
to the outer construction, comprising the breathable outer material
40 and the tongue 42, nor to the assembly insole 44 in the midfoot
portion 92. In this way, the bootie 50 is free to move with respect
to the surrounding elements of the upper assembly in the midfoot
portion 92. A complete freedom of relative motion is established in
the midfoot portion, which provides a comfortable fit to the user.
In particular, the bootie 50 is not attached to the remainder of
the upper assembly 4 in the midfoot portion corresponding to the
region between an upper tongue portion and the beginning of the toe
box area of the upper assembly 4.
[0063] In the midfoot portion 92, the bootie has a smaller
circumference than the wearer's foot. This is illustrated in FIG. 1
as follows. The outer construction of the upper assembly 4,
comprising the breathable outer material 40 and the tongue 42, is
depicted to roughly correspond to the shape and size of the
wearer's foot.
[0064] As can be seen in FIG. 1, an air gap 52 is present above an
upper side of the bootie 50 in the midfoot portion 92. This air gap
52 illustrates that the circumference of the bootie 50 is smaller
than the circumference of the wearer's foot, which roughly
corresponds to the extension of the outer construction.
[0065] The bootie 50 is elastic in a circumferential direction, at
least in the midfoot portion 92. In this way, the bootie 50 is able
to expand upon the insertion of the wearer's foot. This elastic
expansion of the bootie 50 pushes the upper side of the bootie
towards the breathable outer material 40 and the tongue 42 in the
mid-foot portion 92, thus shrinking or eliminating the air gap 52
when the wearer's foot is inserted. The air may escape through the
breathable outer material 40 or through the tongue 42. When
expanding, the bootie exerts a force onto the wearer's foot due to
its elasticity. In this way, the wearer experiences a stable and
comfortable fit in the midfoot portion 92, while the potential for
relative motion with respect to the surrounding part of the upper
assembly 4 ensures freedom to move and increases the experienced
comfort level to the wearer.
[0066] In a particular example of a footwear of shoe size 43, the
bootie may have a circumference of between 200 mm and 225 mm in all
cross-sections along the mid-foot portion. This bootie may have a
circumferential elasticity of about 5 N/cm at 30% elongation in the
midfoot portion. The bootie may or may not have longitudinal
elasticity in the midfoot portion. For example, the bootie may have
a longitudinal elasticity of about 5 N/cm at 10% elongation in the
midfoot portion.
[0067] FIG. 2 shows the footwear 2 of FIG. 1 in a transverse
sectional view. In particular, FIG. 2 shows the footwear 2 of FIG.
1 along the cross-sectional plane indicated by A-A in FIG. 1. The
cross-sectional plane of FIG. 2 cuts through the midfoot portion 92
roughly in the middle thereof.
[0068] As described above, the bootie 50 is completely un-attached
in the midfoot portion 92. This is further illustrate in FIG. 2,
where no glue portions or other attachment means are shown between
the bootie 50 and the surrounding shoe structure, namely the
assembly insole 44, the breathable outer material 40 and the tongue
42. Also, the air gap 52 is again illustrated in FIG. 2. In
particular, the air gap 52 is depicted to have about 20% of the
height of the space between the assembly insole 44 and the tongue
42 in the center of the shoe. While it is pointed out that the
FIGS. are not to scale, but aim at conveying illustrative examples,
the air gap 52 may have a height of between 1% and 20% of the
distance between the assembly insole 44 and the tongue 42. As
described above, in addition to/as an alternative to the air gap
52, a compressible material may be provided between the bootie 50
and the breathable outer material 40/tongue 42.
[0069] FIG. 3 shows footwear 2 in accordance with another exemplary
embodiment of the invention. The footwear 2 of FIG. 3 has
similarities with the footwear 2 of FIGS. 1 and 2. For those
features/elements that are not described with respect to FIG. 3,
reference is made to the description of the footwear of FIGS. 1 and
2 above.
[0070] The footwear 2 of FIG. 3 also has an upper assembly 4 and a
sole 6. The construction of the upper assembly 4 of FIG. 3 differs
from the upper assembly 4 of FIG. 1 in that it does not have an
assembly insole. In other words, the upper assembly 4 of FIG. 3 is
free of an assembly insole, i.e. free of a dedicated structural
element that is arranged underneath the wearer's foot and that
forms the pivot during manufacture of the upper assembly. Rather,
the lower portion of the bootie 50 assumes the function of the
pivot during manufacture of the upper assembly. In other words,
while not being a dedicated assembly insole, the lower portion of
the bootie 50 of FIG. 3 has assembly insole functionality.
[0071] With the upper assembly 4 of FIG. 3 not having an assembly
insole, the breathable outer material 40 is lasted onto the lower
side of the bootie 50. In particular, the third glue portion 74,
which is arranged in the heel region 96, provides for an attachment
between the bootie 50 and the breathable outer material 40.
Analogously, the fourth glue portion 76, which is arranged in the
toe region 90, provides for an attachment between the bootie 50 and
the breathable outer material 40. As compared to the footwear of
FIG. 1, the third glue portion 74 has a shorter longitudinal
extension along the bootie 50. The lasted portions of the
breathable outer material 40 have a greater longitudinal extension
in the FIG. 3 embodiment, as compared to FIG. 1.
[0072] Similar to the FIG. 1 embodiment, the sole 6 of the footwear
2 of FIG. 3 is also an injected sole. However, in the absence of an
assembly insole, the sole 6 of FIG. 3 is injected onto the lasted
portions of the breathable outer material 40 and directly onto the
underside of the bootie 50. When being injected, in particular when
being injection molded, the material of the sole 6 reaches the
bootie 50 and forms an adhesive bond therewith. The material of the
sole 6 also enters into the space between lasted portions of the
breathable outer material 40 and the bootie 50 adjacent to the
third and fourth glue portions 74, 76. Also, the material of the
sole attaches to the underside of the lasted portions of the
breathable outer material 40. In this way, the injected sole
material provides for a strong adhesive bond between the sole 6,
the breathable outer material 40 and the bootie 50. The bootie 50
is thus attached to the sole 6 along its entire underside in the
midfoot portion 92. In particular, the bootie 50 is attached to the
sole 6 along its entire underside between the third and fourth glue
portions 74, 76. It is, however, pointed out that this is not
necessarily the case for all longitudinal cross-sections through
the footwear 2. It will be shown with respect to FIG. 4 that the
attachment between the underside of the bootie 50 and the sole 6 is
confined to a comparably narrow attachment region.
[0073] FIG. 4 shows the footwear 2 of FIG. 3 in a transverse
sectional view. In particular, FIG. 4 shows the footwear 2 of FIG.
3 along the cross-sectional plane indicated by A-A in FIG. 3. The
cross-sectional plane of FIG. 4 cuts through the midfoot portion 92
roughly in the middle thereof.
[0074] As described above, the sole 6 of the exemplary embodiment
of FIGS. 3 and 4 is attached to the lasted portions of the
breathable outer material 40 and to the underside of the bootie 50.
In the midfoot cross-section depicted in FIG. 4, the sole is
attached to the underside of the bootie 50 in a center portion
thereof. The term center portion refers to a region around the
center of the bootie a transverse direction. The attachment between
the sole 6 and the underside of the bootie 50 may be the same or
similar in all transverse cross-sections in the midfoot area. In
this way, the attachment between the sole 6 and the bootie 50 is
confined to a comparably small area. While providing some degree of
stability for the overall footwear construction, the attachment
area is kept small, leading to a highly flexible arrangement of the
bootie 50 within the footwear 2 and to a high level of perceived
freedom to move for the wearer.
[0075] It is pointed out that the attachment area between the sole
6 and the bootie 50 may be adapted according to the requirements of
a particular application. It is for example also possible that the
sole 6 is attached to the bootie 50 across the entire width between
the lasted portions of the breathable outer material 40. The
attachment area can be controlled well during manufacture. A
protective layer may be arranged on the bootie in those portions
that are not supposed to be reached by sole material. This
protective layer may be pulled out from the underside of the bootie
50 along its side portions, after the sole 6 has been injected.
[0076] FIG. 5 depicts the anatomy of the bones of human feet in a
top view. In particular, FIG. 5 depicts the bones of a right foot
100 and a left foot 102, including the extensions of the right and
left feet around the bones, indicated by respective circumferential
lines. The representation of the feet 100, 102 of FIG. 5 is a
standard representation of human feet, as provided in a medicine
textbook.
[0077] In both the right foot 100 and the left foot 102, the
navicular bone is provided with reference numeral 104. The outline
of the navicular bone can be referred to as the navicular area 104
of the foot. Further, in both the right foot 100 and the left foot
102, the metatarsal 1 bone is provided with reference numeral 108.
The front of each metatarsal 1 bone 108 ends in the phalanges
joint. This front end is indicated with reference numeral 106 and
is referred to herein as metatarsal point 1--phalanges joint.
[0078] As described above, it has been found that relative freedom
to move between a bootie and an outer construction on the upper
side of the midfoot portion provides for a high level of comfort to
the wearer of a shoe. It has further been found that providing this
freedom to move along at least 80%, in particular along at least
90%, more in particular along 100%, of the length between the
navicular area 104 and the metatarsal point 1--phalanges joint 106
provides for a particularly high level of comfort to the wearer.
Measured from the front-most portion of the navicular area 104 to
the front-most portion of the metatarsal point 1--phalanges joint
106, this length corresponds to about 40% of the length of the
human foot.
[0079] FIG. 6 shows footwear 2 in accordance with another exemplary
embodiment of the invention. The footwear 2 of FIG. 6 is a
variation of the footwear 2 of FIGS. 1 and 2. In particular, while
the upper assembly 4 of the footwear 2 of FIG. 6 is the same as the
upper assembly 4 of FIGS. 1 and 2, the sole 6 of the footwear 2 of
FIG. 6 is a variation of the sole 6 of FIGS. 1 and 2. FIG. 6 shows
a cross-sectional view analogous to the cross-sectional view of
FIG. 2.
[0080] The sole 6 of the footwear 2 of FIG. 6 is a breathable sole.
In particular, the sole 6 is of a breathable structure. The sole 6
has a circumferential portion 60 and stabilizing bars 62. The
stabilizing bars 62 and the circumferential portion 60 may be
integrally molded from a plastics material. While the stabilizing
bars 62 are depicted as longitudinal bars in the cross-sectional
view of FIG. 6, the stabilizing bars 62 may be arranged in
different directions. In particular, the stabilizing bars 62 may
form a stabilization grid within the circumferential portion 60.
The stabilizing bars 62/the stabilization grid may extend over one
or more portions of the sole 6, e.g. over a forefoot portion of the
sole 6 and/or over a heel portion of the sole 6.
[0081] In between the stabilizing bars 62/stabilizing grid, there
are provided water vapor discharge holes 66. The water vapor
discharge holes 66 are comparably large in diameter and thus allow
for the discharge of large amounts of water vapor through the sole
6. The water vapor discharge holes 66 extend substantially
vertically though the sole 6. Above the water vapor discharge holes
66, there is provided a barrier material 64. In particular, the
barrier material is provided between the circumferential portion 60
of the sole 6, below the assembly insole 44, and above the
stabilizing bars 62. The barrier material is breathable, i.e. water
vapor permeable, and protects the upper assembly 4 thereabove from
foreign objects that may penetrate through the water vapor
discharge holes 66.
[0082] The footwear 2 of FIG. 6 allows for water vapor discharge
through the breathable outer material 40 as well as through the
sole 6. Water vapor can travel from the underside of the wearer's
foot through the bootie 50, through the assembly insole 44, through
the barrier material 64, and through the water vapor discharge
holes 66 to an outside environment of the shoe. With the bootie
being made with a breathable, waterproof laminate, the wearer's
foot is protected from water, also from water entering through the
water vapor discharge holes 66.
[0083] FIG. 7 shows footwear 2 in accordance with yet another
exemplary embodiment of the invention. The footwear 2 of FIG. 7 is
a variation of the footwear 2 of FIGS. 1 and 2. In particular,
while the upper assembly 4 of the footwear 2 of FIG. 7 is the same
as the upper assembly 4 of FIGS. 1 and 2, the sole 6 of the
footwear 2 of FIG. 7 is a variation of the sole 6 of FIGS. 1 and 2.
FIG. 7 shows a cross-sectional view analogous to the
cross-sectional view of FIG. 2.
[0084] The sole 6 of the footwear 2 of FIG. 7 is a breathable sole,
as is the sole 6 of the footwear 2 of FIG. 6. While the sole 6 of
FIG. 6 relies on water vapor discharge towards the bottom of the
sole, the sole 6 of FIG. 7 relies on water vapor discharge towards
the lateral sides of the sole. The bottom surface of the sole 6 of
FIG. 7 is free of water vapor discharge holes. However, it is also
possible that the sole of footwear in accordance with exemplary
embodiments of the invention has water vapor discharge holes
towards the bottom and towards the side.
[0085] The sole 6 of FIG. 7 has a structure or material for
allowing air flow through it, generally indicated with reference
numeral 68. The structure or material 68 may be any suitable
structure or material that allows for air flow theretrough and,
thus, allows for the transport of water vapor, coming from the
inside of the shoe, towards the lateral sides and out of the shoe.
The structure or material 68 may for example be a channel structure
or a spacer fabric or a granulate fill or any other suitable
structure or material. The sole 6 further comprises a plurality of
water vapor discharge holes 66. In the cross-sectional view of FIG.
7, two of the plurality of water vapor discharge holes 66 are
shown. It is understood that a suitable number of water vapor
discharge holes 66 may be arranged around the periphery of the sole
6.
[0086] The water vapor discharge holes 66 are provided from the
structure or material 68 towards the lateral sides of the sole 6.
In particular, the water vapor discharge holes 66 are substantially
horizontal in the exemplary embodiment of FIG. 7. Further, the
water vapor discharge holes 66 are substantially circular in
cross-section in the exemplary embodiment of FIG. 7. However, the
water vapor discharge holes may have any suitable
cross-section.
[0087] The footwear 2 of FIG. 7 also allows for water vapor
discharge through the breathable outer material 40 as well as
through the sole 6. Water vapor can travel from the underside of
the wearer's foot through the bootie 50, through the assembly
insole 44, into and through the structure or material 68, and
through the water vapor discharge holes 66 to an outside
environment of the shoe. Due to the straight air flow path between
the left and right sides of the sole 6, an efficient water vapor
discharge through the sole 6 may be achieved. With the bootie being
made with a breathable, waterproof laminate, the wearer's foot is
protected from water, also from water entering through the water
vapor discharge holes 66.
[0088] FIG. 8 shows exemplary embodiments of laminates that may be
used for the bootie 50 for exemplary embodiments of the invention.
FIG. 8A shows a waterproof, breathable three-layer laminate 51. The
three-layer laminate 51 has a functional layer 54, which is an
ePTFE membrane in the exemplary embodiment of FIG. 8A, a first
textile layer 56, and a second textile layer 58. The first and
second textile layers 56, 58 are knitted layers in the exemplary
embodiment of FIG. 8A.
[0089] FIG. 8B shows a waterproof, breathable two-layer laminate
51. The two-layer laminate 51 has a functional layer 54, which is
an ePTFE membrane in the exemplary embodiment of FIG. 8B, and a
textile layer 56, which is a knitted layer in the exemplary
embodiment of FIG. 8B. The laminate 51 can be used in any
orientation for the bootie 50, i.e. the two-layer laminate 51 can
be used with the functional layer 54 facing the wearer's foot and
with the textile layer 56 facing the wearer's foot.
[0090] Test Methods and Definitions
[0091] A functional layer and a laminate are considered to have
waterproof characteristics in case the requirements specified in
DIN EN 343 (2010) are met, i.e. a test of the liquid water
resistance with respect to hydrostatic water pressure according to
EN 20 811 (1992) yields a liquid water resistance Wp of 8000 Pa, or
more.
[0092] Water vapor permeability, as used herein concerning the
functional layer and the laminate comprising the functional layer,
is tested and defined in EN ISO 15496, also known as the "Cup
Test". A 20.times.20 cm or O100 mm sample of the waterproof,
breathable laminate is placed onto a container containing water and
covered with a membrane. Then a cup containing potassium acetate
and being covered by the same membrane is placed on the sample.
Water vapor passes through the laminate into the cup, whose weight
increase is then determined. The laminate is considered water vapor
permeable or breathable if the water vapor permeability is greater
than or equal to 0.01 g/(Pa*m2*h). If the required size of the
sample cannot be obtained, a smaller sample may be used for the
measurement using a smaller cup containing half the amount of
potassium acetate specified in the Norm, i.e. 50 g instead of 100 g
and mixed with 15.6 g of water. The terms water vapor permeability
and breathability are used interchangeably herein. Accordingly, the
waterproof, breathable laminate may also be referred to as
waterproof, water vapor permeable laminate.
[0093] The waterproofness of footwear may be determined by use of
the Centrifuge test described in U.S. Pat. No. 5,329,807, and
incorporated by reference herein in its entirety. The centrifuge
tests may be carried out for 30 minutes. The footwear article is
considered to be waterproof if no leakage is seen after 30
minutes.
[0094] The breathability of footwear may be assessed in accordance
with the determination of the Whole Boot Moisture Vapor
Transmission Rate Test in accordance with the Department of Defense
Army Combat Boot Temperate Weather Specifications. The
specifications are as follows:
[0095] Whole boot breathability
[0096] The boot breathability test shall be designed to indicate
the Moisture Vapor Transmission Rate (MVTR) through the test sample
by means of a difference in concentration of moisture vapor between
the interior and the exterior environment.
[0097] Apparatus
[0098] a. The external test environment control system shall be
capable of maintaining 23 (.+-.1).degree. C. and 50%.+-.2% relative
humidity throughout the test duration.
[0099] b. The weight scale shall be capable of determining the
weight of test samples filled with water to an accuracy of
(.+-.0.01) gram.
[0100] c. The water holding bag shall be flexible so that it can be
inserted into the test sample and conform to the interior contours;
it must be thin enough so that folds do not create air gaps; it
must have much higher MVTR than the footwear product to be tested;
and it must be waterproof so that only moisture vapor contacts the
interior of the footwear product rather than liquid water.
[0101] d. The internal heater for the test sample shall be capable
of controlling the temperature of the liquid water uniformly in the
test sample to 35 (.+-.1).degree. C.
[0102] e. The sealing method around the collar of the test sample
shall be impervious to both liquid water and water vapor.
[0103] Procedure
[0104] a. Place sample in test environment and condition for at
least 12 hours.
[0105] b. The heating device is inserted into the water holding bag
and the complete assembly is then placed into the test sample
opening and filled with water to a height of 5cm measured from
inside sole.
[0106] c. Seal opening around the collar with plastic wrap around
the top of the footwear and tape over using packaging tape.
[0107] d. Heat water in test sample to 35.degree. C.
[0108] e. Weigh test sample and record as Wi.
[0109] f. Hold temperature in test sample after weighing for a
minimum of 4 hours.
[0110] g. After a minimum of 4 hours, reweigh test sample. Record
weight as Wf and test duration as Td.
[0111] h. Calculate MVTR of the test sample in grams/hour from the
equation below:
MVTR=(Wi-Wf)/Td.
[0112] This test is in accordance with ASTM D8041 (2016).
[0113] For example, for a low ankle shoe of European shoe size 42,
the footwear may be considered breathable if above calculated value
is above 1.5 grams/hour. For larger/smaller shoe sizes, said limit
value may be extrapolated in accordance with the
increased/decreased surface area of the shoe.
[0114] The waterproofness and the breathability of the bootie as a
whole may also be determined by use of the Centrifuge test and the
Whole Boot Moisture Vapor Transmission Rate Test, respectively, as
laid out above.
[0115] The elasticity of the laminate and of the bootie may be
measured according to DIN EN 14704-1 (July 2005), method A. The
test may be carried out as set out therein, while using test
samples of the following configuration: Test sample width=25 mm,
test sample testing length=50 mm (testing length referred in DIN EN
as gauge length, the length of the sample between the tensile
machine clamps), whole length of test sample=100-150 mm. The test
sample is subject to 3 to 5 consecutive test cycles. In each test
cycle, the test sample is subject to a constant extension of 30% of
said gauge length, in samples cut circumferentially and 10% of said
gauge length in samples cut longitudinally to the formed bootie,
and the maximum force of the last cycle is measured. The extension
and retraction rate of the sample should be set to 250 mm/min. The
specimen length is measured after final cycle finishes by laying it
on a flat surface and measuring the length between applied
reference markers within the gauge length with a calibrated ruler.
The elastic recovery expressed in % is calculated through
subtracting the final length between applied reference markers from
the original length between said reference markers, dividing then
by the original length between said reference markers, and finally
multiplying the result by 100. Otherwise, test conditions are as
set out in DIN EN 14704-1 (July 2015), method A. Elasticity is
defined as a property of material in which the material extends at
the application of a force or extension and recovers towards its
original length after removing the applied force or extension. The
elasticity of the specimen is therefore determined via measuring
the force recorded during applied extension (or vice versa) and the
ability of the material to recover towards its original length
after said applied force or extension has been removed.
[0116] While the invention has been described with reference to
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed, but that the invention will
include all embodiments falling within the scope of the appended
claims.
* * * * *